FUTABA Mold Marshalling System MPS08 User manual

Whole or part of this manual may not be copied or reproduced without the written permission of Futaba Corporation.
This manual is a copyrighted work of Futaba Corporation and the copyright belongs to Futaba Corporation.
The contents of this instruction manual may be changed without prior notice.
Mold Marshalling System for
Measuring Resin Pressure inside Molds
Pressure Measuring Amplifier
Instruction Manual
Thank you for your purchasing a product of Futaba Corporation.
Please read this instruction manual carefully and patronize the product for
many years to come.
Do not use the product in any way other than explained in this instruction
manual.
< For Windows >

Safety Precautions
Preface 1
Standard Accessories 1
Handling Precautions 2
System Configuration 3
1. Names and Major Functions of Components 4
1-1 Front 4
1-2 Rear 5
2. Preparation 6
2-1 Setting up Network connections 6
2-2 Installing PC Software 6
2-2-1 Operating Environment 6
2-2-2 Installing the PC Software 6
2-2-3 Checking the version 6
2-3 Updating Software 7
2-3-1 Updating PC software 7
2-3-2 Updating firmware 7
2-4 Installing the System 12
2-4-1 Installing the pressure sensor 12
2-4-2 Installing the Junction box 12
2-4-3 Wiring the Junction cable 12
2-4-4 Installing the amplifier 12
2-5 Connections in System 13
2-6 Connecting the I/O Signal 15
2-7 Connecting the Power Supply 18
3. Basic Operation of Amplifier 19
3-1 Turning Power ON/OFF 19
3-2 Operating the Amplifier 19
3-2-1 Operating the key switches 19
3-2-2 LCD window display 19
3-2-3 Using the amplifier by stand-alone 20
4. Basic Operation of Measurement Software 21
4-1 Starting and Exiting Software 21
4-2 Changing the Language 21
4-3 Names and Functions of Screen
Components 22
4-4 Setting the Conditions 23
4-4-1 Setting measurement conditions 23
4-4-2 Setting sensor sensitivity 24
4-4-3 Setting alarm monitoring conditions 25
4-5 Saving Settings As 27
4-6 Saving Settings 27
4-7 Reading Settings from Amplifier 27
5. Using the System 28
5-1 Selecting Measurement Mode 28
5-2 Selecting Setting File 28
5-3 Starting Measurement 29
5-4 Observing Pressure Waveforms 29
6. Function Description 30
6-1 Displaying Template Waveforms 30
6-2 Overlaying Waveforms 31
6-3 Using the Cursor Functions 31
6-4 Waveform Display Settings 32
6-4-1 Enlarging waveforms 32
6-4-2 Moving the waveform position 32
6-4-3 Displaying the entire waveforms 32
6-4-4 Changing the color of waveforms 33
6-5 Other Display Settings 33
6-6 Saving Data 34
6-6-1 Types of saved data 34
6-6-2 Setting the save folder 34
6-6-3 Displaying storage space 34
6-7 Administrator Settings 34
7. Checking the Operation 36
7-1 Checking the Communication between
Amplifier and PC 36
7-2 Checking the I/O Signal 36
7-3 Checking the Operation of Sensor 37
7-3-1 Sensor calibration 37
7-3-2 Quick sensor checking 37
8. Measuring with an External Measuring Device 38
8-1 Connecting an External Measuring Device 38
8-2 Correlation between Output Voltage and
Pressure Value 39
8-3 Enabling the Voltage Output Function 39
8-4 Observing Pressure Waveforms 39
9. Specifications 40
Contents

Safety Precautions (Be sure to read before use)
Before Use
Before using the product, read this “Safety Precautions”and the instruction manual carefully.
After reading the manual, keep it in a safe place so that it can be used whenever needed.
When using the product, be sure to observe the following safety precautions.
Futaba Corporation assumes no liability for the injury caused by using the product contrary to these
precautions.
This manual uses the following alert symbols for safe use of the product.
General Precautions
When starting product operation, make sure in advance that the functions of the product are normally
working with normal performance.
If the product fails, use adequate safety measures to prevent various types of damage.
Note that we cannot guarantee the functionality and performance for use of the product not conforming to
the specifications or any remodeled product.
When using the product in combination with other equipment, evaluate it thoroughly because the
functionality and performance may not be satisfactory depending on the use conditions and environment.
Precautions
Failure to observe the instructions with this symbol could result in death or
serious personal injury.
WARNING
Failure to observe the instructions with this symbol could result in injury or
only damage to property.
CAUTION
Use the AC adaptor that comes with the product.
Using any other AC adaptor could result in device damage or failure.
CAUTION
When installing the product or connecting cables, be sure to disconnect the power
cable from the outlet in advance.
It could result in electric shock or malfunction.
WARNING
Do not use a broken cable or a cable with a flaw in the covering.
It could result in fire, electric shock, or device damage or failure.
Use the power to the AC adaptor within the range (100 to 240 V) stipulated in the
specifications. Using power outside the range could result in fire or device damage
or failure.
Keep the sensor, amplifier, Junction box, and Junction cable away from water.
It could result in electric shock or device damage.
WARNING
WARNING
WARNING

1
Preface
“Mold Marshalling System”is a system for measuring resin pressure inside injection molds using a strain gage
pressure sensor of Futaba Corporation.
Using the attached measurement software allows you to observe pressure waveforms, store data, and monitor
and set alarms on the personal computer.
Major features are as follows:
A standard system can measure up to eight channels concurrently.
Sensitivity of the pressure sensor can be easily performed. (It only needs to input numbers and alphabet.)
Waveform and historical data of each shot is automatically saved.
Data is saved in CSV format and can be easily read with commercially available spreadsheet software.
Six alarm monitoring items can be set for each channel.
When an alarm occurs, it is possible to output a signal to the robot to sort the defective products.
Even an amplifier alone enables alarm monitoring. (In this case, data is not saved.)
The waveforms being measured can be overlaid on the waveforms saved in the past.
Please read this instruction manual carefully and use the product correctly.
If you have any questions, please contact our sales department.
Standard Accessories
This equipment comes with the following standard accessories.
After unpacking the equipment, make sure that all accessories are included.
- Pressure measurement amplifier “MPS08”: ................................................................................................. 1
- Junction box “UJP04”:..................................................................................1 (or 2 if two boxes are ordered)
- Junction cable “WJP0430”:..........................................................................1 (or 2 if two cables are ordered)
(One ferrite core for noise suppression comes with one cable.)
- AC adaptor “ES0024010”: ........................................................................................................................... 1
(One ferrite core for noise suppression comes with the adaptor.)
- I/O cable “WCI005”:..................................................................................................................................... 1
- LAN cable “WCL0020”:................................................................................................................................ 1
- Software “PPS series”(CD-ROM, the latest version at the time of shipment): .............................................. 1
- Instruction Manual (This Manual):................................................................................................................ 1
- Installation Manual: ..................................................................................................................................... 1
- Warranty and Certificate of Registration:...................................................................................................... 1

2
Handling Precautions
Turn on the power to the amplifier after connecting between the systems. Be sure to connect the power cable
of the amplifier to the AC outlet. Do not turn on/off the power supply by disconnecting and connecting the I/O
cable connector. It could damage the amplifier and AC adaptor.
When the power is once turned off, wait for at least 5 seconds before turning it on again. If the power is turned
on within 5 seconds or turned on and off repeatedly, power failure may be caused by rush current generated at
power on.
Warm up the system before use, for about 30 minutes after power on.
Before turning off the power to the amplifier, be sure to exit the measurement software. If the power is turned
off with the software running, communication operation may not be terminated normally and an unexpected
failure may occur.
When the amplifier is used alone, disconnect the LAN cable only after exiting the measurement software and
turning off the power to the amplifier. If the LAN cable is disconnected with the software running or with the
amplifier power on, communication operation may not be terminated normally and an unexpected failure may
occur.
When turning off the power after setting operation is performed, wait at least 3 seconds. The setting is stored in
the non-volatile memory in the amplifier but is not stored correctly if the power is turned off soon after the
setting operation.
This system stores the data measured by the amplifier in the storage device (such as a hard disk) of PC. To
prevent the degradation of PC performance or unexpected failure, the system is designed to stop saving data
when the amount of stored data exceeds a certain level. Move the data frequently.
When performing measurement in maintenance mode, be sure to execute “set zero point”. Without doing “set
zero point”, pressure cannot be measured correctly.
* When measurement is performed in monitor mode, “set zero point”is executed when the signal (IN1) is
input from the molding machine or when the “SET”key on the amplifier is pressed.
Avoid using the system in an environment subject to remarkably high or low temperature. The allowable range
of operating temperature is 0 to 50°C. If it is unavoidable to use the system at a place subject to direct sunlight
or in a cold area, protect it from sunlight or keep it warm.
Use the system in the relative humidity range from 35 to 85%. Using it out of the humidity range or in an
environment subject to water splashes could result in performance deterioration or failure.
Do not use the system in a dusty place. Performance degrades if the dust gets inside. Prevent dust from
getting inside not only during operation but also during storage. Use the system in an environment in which
personal computers can be used.
If the environment changes drastically, do not operate the system soon. Leave the system in the new operating
environment to adapt it to the environment and then use it. If the ambient temperature or humidity is changed
drastically due to movement, condensation may cause performance degradation and failure.
Do not use the system in an environment subject to vibration or impact. Continuous vibration or large impact
could cause performance degradation or failure.
Do not use the system in strong electromagnetic fields. Use it in an environment in which personal computers
can be used. Using it in the vicinity of a radio, microwave oven, or electric furnace that generates a strong
electromagnetic field could cause performance degradation, malfunction, or failure.
Do not use the system in locations with poor power supply conditions. Use it with a power supply at 100 to 240
VAC, 50/60 Hz, free from momentary power failure and noise.
Do not pull connection cables. Connect each connection cable with a margin so that excessive force is not
applied to the connection. Pulling the cable or applying excessiveforce to it could cause failure, measurement
interruption, or abnormal measurements.

3
System Configuration
The following figure shows a system configuration that measures pressure inside the mold using Mold
Marshalling system “MPS08 series”.
As shown in the above figure, the “MPS08”connects a strain gage type pressure sensor to the input.
The pressure sensor is connected to the Junction box that can accommodate four channels and, via the Junction
cable, connected to the amplifier. Two Junction boxes can be connected to one amplifier.
The amplifier and PC exchange data via the LAN cable. The measurement software that comes with the system
needs to be installed in advance in PC. Pressure waveform data and historical data are stored in PC.
The “MPS08”can run with the amplifier alone. After PC is connected and the setting conditions are stored in the
amplifier, the monitor function works even with PC disconnected. (Data cannot be saved to the amplifier and
therefore only the alarm check function is available if the PC is disconnected.)
Connect the system to the molding machine and peripheral control equipment using the I/O cables that come
with the system. Doing so enables automatic start of measurement, output of alarm signals, and clearing alarm
signals.
The “MPS08”has the voltage output feature, so a commercially available data logger can be connected to
measure pressure waveforms.
Molding machine,
controller
Pressure sensor
Junction box
Junction cable
LAN cable
Voltage output
Data logger etc.
AC adaptor
AC
AC outlet
Ground
I/O cable
Amplifier
PC
CH １２３４

4
1. Names and Major Functions of Components
1-1 Front
①Display panel...................................................Displays the status of measurement, setting file name, shot
counter, and setting conditions in the amplifier.
②Control keys “→”, “↑”, “↓”, “SET”.......................“→” key: Changes the display content when held down.
“↑”, “↓” key: Changes the setting.
“SET”key: Fixes the setting changed.
In monitor mode, pressing this starts measurement. (Usable
as the manual trigger)
①
②

5
1-2 Rear
①Junction box connector....................................Connected to the Junction box using the dedicated Junction
cable. Two Junction boxes can be connected.
②Grounding terminal..........................................Terminal for ground.
③Wired LAN jack................................................Connected to PC using the LAN cable.
④Connector for expansion..................................Reserved for expansion in the future.
⑤I/O cable connector .........................................Inputs a trigger signal and alarm clear signal, outputs an
alarm signal, and also supplies power.
⑥Voltage output connector.................................Connected to external measuring equipment such as the
data logger and oscilloscope.
①
②
③
④
⑤
⑥

6
2. Preparation
This section explains the preparation required before turning on the power.
2-1 Setting up the Network Connections
Make settings for communication between the amplifier MPS08 and PC.
* For the Network Connections procedure, refer to the “Measurement Software (PPS) Installation
Manual”.
2-2 Installing PC Software
2-2-1 Hardware Requirements
Operation system
This software has been checked normal operation with the following operation systems.
Windows XP(32bit), Windows 7(32bit), Windows 7(64bit), Windows 8(32bit), Windows 8(64bit)
Capability
For your pleasant use of software, the recommended specifications of PC are:”Core2 Duo”CPU and 1GB or
more memory. Approximately, it may be a PC with 1GB memory released in 2007 or later.
2-2-2 Installation
* For the installation procedure, refer to the “Measurement Software (PPS) Installation Manual”.
2-2-3 Checking the version
The version of the software currently used can be checked.
* Unless there is particular reason, always use the latest software for operation.
From the main menu, select [About ...] →[About...].
PC software version on the upper
row
Amplifier software version on the
lower row

7
2-3 Updating Software
This section describes how to update the PC software and amplifier software (hereafter referred to as
firmware).
* For the acquisition of the latest software, contact the nearest Futaba sales office.
2-3-1 Updating PC software
Execute the installer file. ( Extension name is “msi ”.)
It is no need to remove the old version software previously installed on PC.
2-3-2 Updating firmware
Step 1: Select “Update firmware”from “System”in the main menu.
Step 2: The file specification window appears.
Select the file and click “Update firmware”.
Step 4: If the firmware is updated successfully,
the message shown at right is displayed.
Press OK to finish.
* After the firmware is updated, the amplifier restarts. So, even when the above message is displayed, do not
turn off the power until the amplifier completes the restart. (It takes about 10 seconds.)
Step 3: Firmware update begins.

8
■In the case of the failure of Firmware updating
There is possibility to cause the failure of firmware updating when the firewall is working on Windows7 or
Windows8. In this case, you can perform the firmware updating by the either methods as follows.
（1）Turning off Windows Firewall
（2）Turning off Firewall application filter for FTP client
These methods should be performs under the supervision of your internet administrator.
(1) Method of turning off Windows Firewall
Step1：Push [Start] Button and click [Control Panel]
Step2：Click [System and Security]
Step3：Click [Windows Firewall]

9
Step4：Click [Turn Windows Firewall on or off]
Step5：Select [Windows Firewall on (Not recommended)] and push [OK]
These setting changes should be done under the supervision of your internet administrator.

10
(2) Method of turning off Firewall application filter for FTP client
Step1：Push [Start] button and select [Accessories].
Right click [Command Prompt] and click [Run as administrator]
These methods should be performs under the supervision of your internet administrator.
Click [Yes] when User Account Control shows.

11
Step2：Execute the following command on the Command Prompt
netsh advfirewall set global StatefulFTP disable
This setting change should be done under the supervision of your internet administrator.

12
2-4 Installing the System
2-4-1 Installing the pressure sensor
For the procedure for installing the sensor on the mold, refer to the “Pressure sensor installation reference
diagram”attached to the purchased sensor.
2-4-2 Installing the Junction box
Install the Junction box near the mold. The temperature limit is 70°C. Be careful not to expose it to temperature
higher than that.
The following three ways of installation are available. In any ways, install the box so that the sensor cable does
not get caught or is not pulled during movement of the mold.
①Screw the box near the mold. (The customer is requested to perform M4 tapping.)
②Fix the box using magnets (sold separately) near the mold.
* Magnets may come off and cause unexpected loss. Use them at customer's own risk.
③Fix the box using mounting fixtures (brackets, L-shaped angles etc. to be prepared by the customer).
* When opening or closing the mold, be careful not to make the pressure sensor cable and the Junction cable
get caught in the mold.
2-4-3 Wiring the Junction cable
Wire the Junction cable in such a way that the cable connectors (on both ends of the Junction box and amplifier)
are not pulled while the mold is opened or closed. The temperature limit is 70°C. Be careful not to expose it to
temperature higher than that.
* It is convenient to use commercially available cable clamps (an example is shown in the photo below).
2-4-4 Installing the amplifier
Prepare a dedicated placing table and put the amplifier on the level surface. Operating temperature ranges from
0 to 50°C.
* Do not move the placing table. If it is moved during measurement, the cables are pulled, which could result
in not only measurement failure but also damage to the system.
Amplifier placing table
Amplifier
Junction box
Sensor cable
Junction cable
Cable clamp
(Commercially
available)

13
2-5 Connections in System
Connect the components in order of the numbers shown in the following figure.
Connect the power supply ⑨after completing the connections ①to ⑧.
①Connect the sensors to the Junction box.
While aligning the red marks on each of the Junction box connector and sensor plug, insert the plug.
Ensure that the sensor plugs are inserted to the bottom.
Bad: Not inserted to the bottom.
OK: Inserted to the bottom.
Molding machine,
controller
Pressure sensor
Junction box
Junction cable
LAN cable
Voltage output
External measuring
instrument etc.
AC adaptor
AC
AC outlet
Ground
I/O cable
Amplifier
②
③
⑥
⑦
⑨
④
⑤
⑧
Ferrite core (E04SR241336A)
Ferrite core (E04SR200935A)
PC
①
CH １２３４

14
②Connect the Junction cable to the Junction box.
Make sure that the two locks on both sides of the connector are locked with a “click”.
③Connect the Junction cable to the amplifier.
Make sure that the two locks on both sides of the connector are locked with a “click”.
* Before doing the above, attach the ferrite core for noise suppression, which comes with the product, to the
Junction cable on the amplifier connection side. Attach the ferrite core by winding the cable one turn around
the ferrite core.
④Connect the LAN cable to the amplifier and PC.
Make sure the connector is locked with a “click”.
⑤Connect the I/O cable and AC adaptor connectors.
* Before doing the above, attach the ferrite core for noise suppression, which comes with the product, to the
cable on theAC side of the AC adaptor.
“Click”
“Click”
“Click”
“Click”
Ferrite core part No.: E04SR241336A
Ferrite core part No.: E04SR200935A

15
⑥Connect the I/O cable to the amplifier.
⑦Connect the I/O cable to the I/O signal device.
Refer to Section 2-6, “Connecting the I/O Signal”. (→Page 15)
⑧Connect the external measuring device (to output voltage).
Refer to Section 8-1, “Connecting an External Measuring Device”. (→Page 38)
⑨Connect the power supply.
Refer to Section 2-7, “Connecting the Power Supply”. (→Page 18)
2-6 Connecting the I/O Signal
<<What is the input signal?>>
The input signal means a signal input to the amplifier from an external device such as a molding
machine or ejector machine.
Trigger signal Required to start measurement. Upon input of the trigger signal, “zero point resetting”is
performed. Input the trigger signal under the condition with no pressure loaded to the sensor.
Unless there is any specific reason, connect the “mold closing complete signal”.
* It takes about 0.1 second for zero point resetting. If the injection start signal is used as a trigger, zero point
resetting may not be finished in time and accordingly normal measurement may not be performed.
ClearAlarm signal Connected to clear the alarm signal being output from the amplifier. Connect the signal as
needed.
* The alarm signal can be cleared automatically by specifying the time in the software settings. (→Page 23)
If automatic clear at the specified time causes no operational problem, the connection of the Clear Alarm
signal can be omitted.
<<What is the output signal?>>
The output signal means a signal output from the amplifier to an external device such as a molding
machine or ejector robot.
Alarm signal An alarm signal is output when the monitoring range defined by software is exceeded.
This signal is used to check for defective items and control external devices such as to stop
the molding machine.
* Alarm monitoring can be set for eight channels individually but the alarm output signal is one for all
channels.

16
Wire these signal wires to the DSUB9 connector of the I/O cable by referring to the following.
* At least the trigger signal must be wired (Close Mold signal etc.) to continuously monitor the pressure
waveforms in the mold.
●DSUB9 connector pin connections
Pin No.
Signal name
Pin connection
1
Trigger
2
Clear Alarm
3
Alarm Output
4
Blank
5
Blank
6
COM (IN)
7
COM (IN)
8
COM (OUT)
9
Blank
●Input signal circuit specifications (trigger signal, clear alarm signal)
Input the signal to the amplifier via the electromechanical relay.
Do not apply voltage.
Example 1: When the output of the molding machine connected to the amplifier is “relay output”
Example of connection of input signal when the molding machine output signal is contact output
Trigger or clear alarm
Molding machine output signal
Electromechanical relay
DCV relay
Molding machine
output signal
Trigger or clear alarm
Solid state relay

17
Example 2: When the output of the molding machine connected to the amplifier is “voltage output”
Connect the signal by using a relay adaptable to the output voltage of the output signal from the molding
machine.
* When using an electromechanical relay, use a relay equipped with the coil surge absorption circuit.
Example of connection of input signal using a relay when the molding machine output signal is DCV
ON/OFF output
●Output signal circuit specifications (alarm output)
The alarm output from the amplifier is up to 100 mA (30 V or less)
in the NPN open collector.
Use the power supply with the negative side connected to the
ground.
Example: Connect I/O signals using the 24 VDC power supply and 24 VDC relay.
* When using an electromechanical relay, use a relay equipped with the coil surge absorption circuit.
* Use an independent power supply separate from the power supply for the molding machine.
Trigger or clear alarm
DCV relay
Molding machine output signal
Relay in molding machine
(close mold signal etc.)
24 VDC relay
Alarm signal
connection
destination
Alarm output
←100 mA or less
24 VDC
power supply